DNP Develops Aseptic Filling System for PET Bottles

Dai
Nippon Printing Co., Ltd. (DNP) has developed an aseptic filling system for
use with Polyethylene Terephthalate (PET) based plastic bottles that facilitates
significant reductions in water usage compared with currently available systems.
The Company is also pleased to announce that the newly developed system has
been adopted by a domestic beverage manufacturer.

The DNP PET aseptic filling system forms PET bottles by inflating a test-tube
like preform in an aseptically preserved chamber. The bottle is then filled
with contents that have been sterilized at high temperatures in just a short
time before being rapidly cooled to allow for filling at room temperatures.
DNP maintains a leading domestic share in the market for this PET aseptic filling
system.

As a result of this latest development that uses hydrogen peroxide in the
sterilization process, it has become possible to reduce water usage by 90% compared
to currently available systems. This is achieved by making use of the residual
heat generated when molding the bottle, allowing for the omission of the washing
process using sterilized water following sterilization.

DNP has also enhanced environmental responses, and supports efforts by beverage
manufacturers to reduce their environmental burden. For example, the Company
has reduced the weight of the heat and pressure resistant plastic bottles used
with carbonated drinks, and has reduced the weight of plastic bottles used with
contents other than mineral water, such as Japanese teas and juices, to the
lightest domestic levels at 14.6g for a 350ml-550ml bottle.

[Background and Activities to Date]

During the 1990's, so-called hot-filling was the mainstream process used
to fill plastic bottles with contents that had been sterilized by heating to
approximately 85-90 centigrade. As a result, beverage manufacturers used sturdy
bottles with a wall thickness that could withstand high temperatures. DNP developed
packaging technology for filling with sterilized contents from 1973, successfully
creating potion packs for the milk served with coffee at coffee shops and restaurants,
and filling equipment for cup-like containers for yoghurt and chilled drinks.
In 1994, the Company developed the aseptic filling system for PET-based plastic
bottles. This system molds plastic bottles from preforms at the same time as
filling with contents, and as it is hence, possible to deliver the small preforms
to the filling factory, significant reductions in environmental burdens can
be achieved compared to instances of transporting the bottles in an inflated
state. As filling can also be conducted at room temperature, numerous cost-based
benefits can be gained from being able to use thin, light weight bottles. This
helps explain the extensive adoption of the DNP-developed system by beverage
manufacturers both in Japan and overseas to date. In recent years, manufacturers
have increasingly expressed the desire for reduced water usage to facilitate
further reductions in their environmental burdens. And in answer to these needs,
DNP has successfully developed an aseptic filling system for use with plastic
bottles that significantly reduces water usage, compared to currently available
systems, without losing any of the systemic functionality.

[Features of Latest Aseptic Filling System]

By unifying the PET bottle molding equipment with the filling equipment,
and prolonging the air-rinse drying with a hot wind that makes use of the
residual heat from molding, it is no longer necessary to wash the inside
of the bottle with sterilized water to remove the hydrogen peroxide used
for sterilization. As a result, compared to systems where the molding equipment
and the filling equipment were previously separated, it has been possible
to cut water usage by approximately 90% - from 24.8 tons per hour to 2.7
tons per hour, based on a calculation of systems capable of filling 600
bottles per minute.

With the newly developed aseptic system for PET-based plastic bottles
that can also be used with carbonated drinks, in addition to reduce water
usage, it is now also possible to reduce the weight of heat and pressure
resistant plastic bottles.

Regarding contents other than mineral waters, in FY 2015 DNP has successfully
pursued further transportation efficiencies.by commercializing a 14.6g product
(for use with 350mm-550ml plastic bottles) that is among the lightest available
on the domestic Japanese market.

[Looking Ahead]

DNP is engaged in the development, not only of systems that reduce water
usage, but also of those capable of reducing necessary energy, such as electrical
power and steam, as well as the use of chemical agents. Looking ahead the Company
will promote the enhancement of environmental responses in aseptic filling systems
for PET-based plastic bottles, and support efforts by beverage manufacturers
to reduce their environmental burdens.

* DNP has positioned Knowledge and Communication, Food and Healthcare, Lifestyle
and Mobility, and the Environment and Energy as growth areas, and is engaged
in the creation of new values. As part of those activities, in addition to focusing
on the development of environmentally friendly products and services, the Company
is also promoting the reduction of the environmental burden throughout the entire
supply chain, including greenhouse gasses, and water usage.

* Product prices, specification and service contents mentioned in this news
release are current as of the date of publication. They may be changed at any
time without notice.